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PDF Content Summary: DIN STANDARD HORIZONTAL END SUCTION CENTRIFUGAL PUMP SERIES Installation,Operation and Maintenance Manual Table of Contents Operating and Service Manual for DIN END SUCTION CENTRIFUGAL PUMP SERIES
FOREWORD 3 ......................................................
GENERAL INFORMATION 4 ................................... RECEIVING AND INSPECTION 5 ............................... INSTALLATION 6-7 .................................................. OPERATION 8-9 ..................................................... DRAWINGS DIN 1 POWER FRAME 10 ........................... ......................... DIN 2 -3 POWER FRAME 11 PACKING SEAL 12 ...................................... CARTRIDGE SEAL 12 ................................... CLOSED COUPLED STYLE 13 ........................ CDM STYLE 13 ........................................... ................................... MALFUNCTIONS / CAUSES 14 ........................ SPARE PARTS RECOMMENDATIONS 14 PUMP TIPS 15 ......................................................... This manual is for a reference guide only. Pumps are built in many variable con gurations and with di erent options. Please consult with the factory for more information regarding your individual product. 2 Forward Operating and Service Manual for DIN END SUCTION CENTRIFUGAL PUMP SERIES The design, craftsmanship and materials used in Gusher Pumps provides for optimum performance and long, trouble-free service. As with any mechanical device, proper use and periodic maintenance will enhance the performance and life of your pump. This manual is provided as a guideline for proper installation, operation and maintenance. THIS MANUAL MUST BE READ AND UNDERSTOOD BEFORE INSTALLING AND OPERATING ANY PUMP. Supervision by an authorized Gusher representative is recommended to insure proper installation. ! This operating and maintenance manual contains important notices and warnings. Please read carefully before installation, electrical connection and initiation. Further instructions concerning the components of the pump must be observed. WARRANTY Gusher Pumps, Inc. will replace or repair at our discretion, within one year of shipment from our plant, any pump in our judgement that has failed due to defects in materials or workmanship, provided the pump has been properly installed and maintained and has not been subjected to abuse. These pumps must be returned to Gusher Pumps, Inc. with complete history of service for inspection and warranty consideration. Gusher Pumps, Inc. does not accept the responsibility for transportation to and from our plant. Furthermore, we do not assume any responsibility for consequential damage or loss of production. Warranty is only valid if genuine Gusher parts are used. CONTACT GUSHER: 22 Ruthman Drive, Dry Ridge, Kentucky, USA 41035 PH: 859-824-5001 FAX: 859-824-3011 gusher.com 3
Heavy-Duty Casings All sizes are self-venting with centerline discharge. All sizes have drain plugs. Heavy-Duty Shaft-minimum de ection increases life for less maintenance. Wear Rings Renewable carbon wear rings. Shaft Sleeve - Renewable Shaft Sleeve eases maintenance (easily removed) General Information Rabbeted Fits-Accurately machined rabbets ensure positive alignment, longer seal life, easy replacement of spare rotating element when maintenance is required. Contained Casing Gasket-Protects against blow-out. 3 POWER FRAME SIZES: MODELS WITH DIN 1 POWER FRAME
and is releaved to allow for changes in temperature. Lubrication: 32-125 40-125 50-125 65-125 32-160 40-160 50-160 65-160 32-200 40-200 50-200 65-200 32-250 40-250 50-250 80-160
Standard pumps are with sealed for MODELS WITH DIN 2 POWER FRAME
life ball bearings. Oil Lubrication is optional Grease Lubrication is optional 40-315 80-200 100-200 100-250 50-315 80-250 100-250 150-200 65-250 80-215 100-315 150-250 65-315 100-160 125-200
MODELS WITH DIN 3 POWER FRAME
Direction of Pump Shaft Rotation: Clockwise when viewed from coupling. Counter clockwise when viewed from pump inlet. 80-400 150-315 100-400 150-400 125-315 125-400
Nameplate Information On every Gusher pump is a nameplate that provides information: 1) The pump’s hydraulic characteristics 2) Pump model number 3) Impeller number and diameter 4) Serial number Since over time, these nameplates can become damaged or removed, it is recommended that all name plate information be recorded for future reference. Having this information will insure proper spare parts or a replacement pump are supplied. 4 Receiving and Inspection
Gusher Pumps, Inc. has taken great care in preparing your pump for shipment, However, due to circumstances beyond our control, your shipment may be received damaged. Therefore we strongly recommend you take a few minutes to check your pump upon receipt. Check for cracked, bent, severely misaligned (minor misalignments almost always occur during shipment), or even missing parts. If any such damage has occurred, you must report it to the delivering carrier and Gusher Pumps, Inc. immediately. We also recommend that you check the model number, horsepower, current characteristics, g.p.m., and ft. head of the pump received to insure that you have received the pump you ordered for your speci c operating conditions. if you should nd some discrepancy, report it to Gusher at once. Storage If your pump is not going to be installed within six months, several precautions must be taken: 1. Preservative treatment of bearings and machined surfaces is required. (Not required for sealed for life ball bearings). 2. Remove packing on pumps with stu ng box. The stu ng box and shaft sleeve must be oil lubricated to also protect against moisture. 3. Units equipped with mechanical seals must also be lubricated with an oil can through the NPT port while rotating the shaft by hand. 4. Pump suction and discharge points must be covered to prevent foreign material from getting into the pump and causing damage while the pump is started at a later date. 3. Pumps must be stored in a dry location. 4. Rotate pump shaft several times every other month. Handling ! WARNING ! Pump and components are heavy. Serious physical injury or damage to equipment should occur from failure to properly lift and support pump. Steel-toed shoes must be worn at all times. Use care when moving pumps. Lifting equipment must be able to su ciently support the entire pump. Refer to Figs. 2a, b, c for proper lifting techniques. FIG. 2a FIG. 2b FIG. 2c
When preparing your pump for Installation PREPARATION bearing housing. The bearing housing must installation, the discharge and suction ports must be clean and free of anything that might prohibit a tight connection. This is especially important on the suction. Air leaks can cause a pump to operate poorly or to lose prime completely. If your pump has been taken out of storage, all the grease, oil or preservative must be removed from the ball then be thoroughly cleaned with kerosene or carbon tetrachloride and relubricated. This is not required on sealed for life bearings. On packed pumps, it will be necessary to clean the shaft sleeve and stu ng box with kerosene or carbon tetrachloride and then repack.
LOCATION / FOUNDATION
Whenever possible, locate the pump far enough below the minimum liquid level in the resevoir so there will be a positive head on the suction at all times. Where this is not possible, the pump should be located as near to the source of supply as possible. Allow ample room for inspection and maintenance. The foundation should be of heavy construction to reduce vibration and must be rigid enough to resist the torque it may be subjected to.
Customers mount the bases in a variety ways. Grouted, welded to other steel, bolted to concrete oor, etc. It should be noted at this time that SPECIAL CARE must be taken when leveling your pump base for coupling alignment, This is of the utmost importance. Once the base is in place and before securing the base, the coupling alignment should be veri ed. The coupling alignment should be checked again once the base mounting is nished. After the base is mounted, the only way to adjust the coupling alignment is by adding or removing shims underneath the motor feet. Level baseplate to within 0.125” over the length and to within 0.062” over the width by adjusting the wedges.
COUPLING ALIGNMENT ! WARNING ! Coupling alignment should be checked and
Before starting any alignment procedure, ensure that the motor power is locked out. Failute to do this will result in serious physical injury. For trouble-free operation of this unit, proper alignment must be attained. Proper alignment is the responsibility of the installer and user of this pump. veri ed: 1) Base installed but not secured 2) Base in place and secured 3) After connecting the system piping 4) Before start-up of a system Review page 9 for coupling alignment speci cations.
Guidelines for piping are given in the SYSTEM PIPING 4). Liquid coming back into the resevoir “Hydraulic Institute Standards” available from the Hydraulic Institute, 30200 Detroit Road, Cleveland, OH 44145-1967. These guidelines should be followed to ensure proper pump operation. ! WARNING ! Never force piping into position by pulling it place with the pump suction and discharge ange bolts. This will cause misalignment between pump and driver which will adversely a ect the operation of the unit, resulting in physical injury and damage to the equipment. 1). All piping must be supported independently of the pump. 2). Before connecting the piping to the pump, ensure that the base is secured. 3). Clean all pipe parts prior to installation. Suction Piping ! WARNING ! NPSH must always exceed NPSH as A R shown on Gusher performance curves. Reference Hydraulic Institute for NPSH and pipe friction values needed to evaluate suction piping. Properly installed suction piping is necessary for trouble-free pump operation. Flush suction piping before connection to the pump. 1). Never place a pipe line elbow in the horizontal plane directly at the pump suction. Use a straight pipe four to six pipe diameters long between the elbow and the pump suction. 2). Use suction pipe one or two sizes larger than the pump suction, with an eccentric reducer, sloping slide down, at the suction ange. Suction piping should never be smaller than the pump suction. 3). Never throttle the pump on the suction side. Always control ow by throttling on the discharge side of the pump. should not enter near the pump suction pipe and the liquid should not drop from a high level. 5). An isolation valve should be installed in the suction pipe at least 4 pipe diameters from the suction to allow closing of the line for pump inspection and maintenance. 6). Pipe should be free of air pockets. 7). Piping should be level or slope gradually downward from the source. 8). No part of the piping should extend below pump suction ange. 9). The size of the entrance from the supply should be one or two sizes larger than the pipe. Discharge Piping 1). A gate valve and check valve should be installed in the discharge line. The check valve should be installed between the gate valve and the pump. This will allow for inspection of the check valve. The gate valve is required for priming, ow regulation and for maintenance of the pump. The check valve is required to prevent pump or seal damage from reverse ow through the pump when the motor is turned o . 2). If quick closing valves are installed in the system, cushioning devices should also be installed to protect the pump from surges and water hammer. 3). A pressure gauge should be installed in the piping just above the pump discharge. This gauge should be located at the pump discharge and before any valves, elbows or other devices. Final Piping Check After all piping connections have been made to the pump: 1) Rotate the shaft by hand to insure that there is no binding and all parts are free. 2) Re-check pump alignment to detect any pipe strain. If pipe strain exists, correct piping.
Check Rotation PREPARATION FOR START-UP Couple Pump and Motor Operation
1). Wire the motor according to motor manufacturers speci cations and according to state and local regulations. 2). Lock out power to driver. 3). Disconnect motor/pump shaft coupling to prevent dry operation of the pump when checking rotation. ! WARNING ! Operating the pump dry will cause damage to the mechanical seal and may cause the rotating parts to seize. 4). Make sure everyone is clear. Jog the motor. Determine if the motor shaft rotation is correct. Refer to page 4 to determine proper motor shaft rotation. Correct if necessary. 1). Lock out power to motor to prevent accidental rotation and physical injury. 2). Install and lubricate coupling per manufacturers instructions 3). Verify coupling alignment. Review page 9 for coupling alignment speci cations. 4). Install coupling guard. ! WARNING ! Never operate a pump without the coupling guard properly installed. Personal injury can occur if pump is run without coupling guard.
1). Open all inlet piping valves 100%. 2). Open discharge valve 10-15% 3). Remove vent plug on casing to insure pump has liquid inside the casing. 4). Review pump nameplate and obtain the pressure the pump was rated for. 5). If your pump is packed, loosen packing gland screws to allow free leakage. Then tighten screws uniformly on packing gland until leakage is reduced to approximately 30 drops per minute. Never tighten packing enough to stop all leakage as a slIght leakage is required to lubricate packing and prevent scoring of shaft sleeve. 6). Start motor and immediately observe pressure gauges. If discharge pressure is not quickly attained, stop the pump and attempt to restart. If pressure is still not obtained, turn the pump o and investigate the cause. 7). Open the gate valve in the discharge line gradually as the motor reaches full speed. (approximately 5 to 10 seconds). Adjust valve to obtain the pressure reading as per the pump nameplate. 8). Check pump for vibration levels, bearing temperature and excessive noise. If normal levels are exceeded, shut down and investigate.
1). Always vary the capacity with gate valve in the discharge line. Never restrict intake ow. 2). If the speci c gravity of liquid being pumped is greater then originally assumed or if the rated ow is exceeded, the motor may overload.
3). Drain all liquid from inside of the pump if it will be exposed to freezing conditions while idle. The conditions could cause liquid to freeze and damage the pump. Liquid inside cooling coils, if supplied, should also be drained. 4). If your pump is packed, nal leakage adjustment will be done with the pump in operation. Tighten screws uniformly on packing gland until leakage is reduced to approximately 30 drops per minute. Never tighten packing enough to stop all leakage...a slight leakage is required to lubricate packing and prevent scoring of shaft sleeve. 5). To prevent damage from cavitation or recirculation, always operate pump at or near rated conditions. ! WARNING ! DO NOT operate pump below minimum rated ows or with suction or discharge valves closed. These conditions could create an explosive hazard due to vaporization of pumpage and can quickly lead to pump failure and physical injury
1). Run the unit under actual operating conditions long enough for the pump and motor to reach operating temperature. 2). Check alignment while unit is still hot. 3). Make any necessary adjustments and reinstall the coupling guards.
COUPLING ALIGNMENT PROCEDURE Alignment Criteria
Angular Alignment Check angular alignment with a micrometer or caliper. Measure from the outside of one ange to the outside of the other ange at intervals around the periphery of the coupling. DO NOT rotate the coupling. The di erence between the maximum and the minimum must not exceed .010”. Motor Shaft Angular Misalignment Pump Shaft Parallel Alignment Check parallel alignment by placing a straight edge across the two coupling anges and measure the o set at various points around the periphery of the coupling. DO NOT rotate the coupling. If o set exceeds .010”, realign the coupling. Motor Shaft .010 Parallel misalignment Straight edge Pump Shaft
DIN 1 (SMALL) POWER FRAME Models for DIN 1 Power Frame 1
32-125 40-125 50-125 65-125 3 1 2 32-160 40-160 50-160 65-160 9 32-200 40-200 50-200 65-200 4 11 10 32-250 40-250 50-250 65-250 5 6 12 13 7 14 8 15 16 17 1819 20
Part Description Number Description
1 Bearing Retainer 2 Ball Bearing 3 Shaft 4 Ball Bearing 5 Bearing Housing 6 Pedestal 7 Gasket 8 Shaft Sleeve 9 Seal Gland 10 Gasket 11 Mechanical Seal 12 Spacer Sleeve 13 Stem Plate 14 Gasket 15 Impeller Drive Key 16 Impeller 17 Washer 18 Impeller Locking Nut 19 Wear Ring 20 Impeller Housing
10 Power Frame 2 & 3 DIN 2 & 3 (LARGE) POWER FRAME
Models for DIN 2 Models for DIN 3 125-400100-400
40-315 65-315 80-315 100-250 125-250 1 2 9 10 50-315 80-200 100-160 100-315 150-200 3 11 1213 65-250 80-250 100-200 125-200 150-250 4 6 5 80-400 6 14 150-315125-315 150-400 7 8 15 16 17 18 19 20 21
Part Description Number Description
1 Bearing Retainer 2 Ball Bearing 3 Shaft 4 Ball Bearing 5 Ball Bearing Housing 6 Pedestal 7 Gasket 8 Shaft Sleeve 9 Seal Gland 10 Gasket 11 Mechanical Seal 12 Locking Collar 13 Stem Plate 14 Gasket 15 Wear Ring 16 Impeller Drive Key 17 Impeller 18 Wear Ring 19 Washer 20 Impeller Locking Nut 21 Impeller Housing
11 Seal Types CARTRIDGE MECHANICAL SEAL AND PACKING 1 1
2 CARTRIDGE TYPE Mechanical Seal Pump Number Description: 1...Cartridge Seal 2...Gasket 2 3 PACKING PUMP Number Description: 1...Packing Gland 2...Packing 3...Packing Seat Washer
For all other parts descriptions, refer to pages 10 and 11 This illustration is for reference only. Your product may vary. Please consult with Gusher Pumps for any other information you may require. 12
PUMP STYLE 1 3 4 2 6 5 1 2 CLOSED COUPLED STYLE Number Description: 1...Motor with Shaft 7 2...Gasket 8 3...Seal Gland 4...Gasket 9 5...Ball Bearing Housing 6...Mechanical Seal 7...Key 8...Bolt 9...Washer 3 CDM STYLE Number Description: 1...Motor 2...Barrel 3...Coupling
For all other parts descriptions, refer to pages 10 and 11 This illustration is for reference only. Your product may vary. Please consult with Gusher Pumps for any other information you may require. 13 Troubleshooting and Spare Parts MALFUNCTIONS / CAUSES Malfunction ) t Cause g n ip m u P o N t u pt u O g n ip m u P t u pt u O e lt ti L o o T e r u s s e r P p U- d li u B e lt ti L o o T g n ip m u P s p o t S t u pt u O t r a t S r e tf A s n o it a r bi V r o to M t o H s e m o c e B n o it a ti v a C e s io N( n e m p o l e v e D
Pump not lled, tubing not deaired x x
Speed too low x x x x x x
Speed too high Suction line leaky x x x x x
Air or gas lock in the pumping medium x x x x x x
Counterpressure too high Suction head too high x x x x Feed pressure too low with hot pumping medium x Tubing on suction side not su ciently covered with liquid x x x x x x xx Density of pumping medium too high Viscosity of pumping medium too high xxx x x Impeller obstructed Tubing on suction side obstructed x x x x x x xxx Wrong rotation Split rings worn out Impeller damaged Driving motor defective Voltage too low Frequency too low Running on 2 phases Installation / foundation unstable Motor - pump not well aligned Bearing worn out xxx x x x xxx x x x x
Balance error in the impeller Impeller too small SPARE PARTS x x x
Gusher recommends that the following spare parts be kept in stock to decrease the customer’s down time...
1). Impeller 2). Wear Rings 3). Ball Bearings 4). Shaft Sleeve 5). All necessary gaskets 6). Mechanical seal (if applicable) 7). Packing (if applicable) 8). Shaft 9). Impeller Drive Key 10). Impeller Retaining Washer 11). Impeller Retaining Nut 12). Coupling Insert
Pump Tips . Never operate a pump without coupling COUPLING GUARDS guards properly installed. . Never force piping to make connection CONNECTIONS . Use only fasteners of proper size and with a pump. . Ensure there are no missing fasteners. material. . Beware of corroded or loose fasteners. . Standard pumps are with sealed for LUBRICATION . Oil lubrication is optional. life ball bearings. . Grease lubrication is optional. . If lubrication information is required, consult the factory. . Never operate below minimum rated OPERATION ow or eith suction/discharge valves . Do not open vent or drain valves, or closed. remove plugs while the system is . Pump should not be allowed to operate pressurized. in a dry mode. This will cause damage to mechanical seals, packing and other pump parts. . Never apply heat to remove impeller. MAINTENANCE SAFETY . Always lockout power. . Ensure pump is isolated from the system and pressure is relieved before disassembling pump, removing plugs . Use proper lifting and supporting or disconnecting piping. equipment to prevent serious injury. . Must always have liquid for lubrication. MECHANICAL SEALS . Double type mechanical seals must have an external supply source of liquid. This external liquid must be circulated through the seal chamber at a pressure equal to or greater than the pump discharge pressure at all times. . Packing must be allowed to leak. This PACKING leakage is the lubrication between the packing and the shaft / sleeve. . Maximum pump shaft end play is SHAFT END PLAY 0.031” . Maximum start / stop cycles per hour STOPPING / STARTING CYCLES is 6. Consult the factory if more cycles are required
CONTACT GUSHER: 22 Ruthman Drive, Dry Ridge, Kentucky, USA 41035 PH: 859-824-5001 FAX: 859-824-3011 gusher.com 15
gusher.com Additional Ruthman Company Partners: Midwest Service Center Superior Engineered Systems 1850 N. Carpenter Rd Titusville, FL 32796 Phone: 321-747-0733 Fax: 321-747-0529 Web: superiorengineeredsystems.com Ruthman Companies Worldwide: Incorporating Beresford Pumps Gusher Pumps, Shanghai ROOM 4012, Polar Star Business Plaza No. 913 Changlin Road, Shanghai, China 200443 Phone: 86-021-26616611 FAX: 86-021-26328038 上海市长临路913号 北斗星广场 4012 室 邮编：200443 电话：86-021-26616611 传真：86-021-26328038 Email: firstname.lastname@example.org China Mobile: 13402145203 USA Mobile: 513-607-4449 Ruthman Companies Corporate Headquarters ruthmancompanies.com
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